Safety & Operation Manual

Transcription

1 47232-Rev A Safety & Operation Manual GA 60 Model GB

2 GENERAL INFORMATION Additional manuals are available through your dealer. IMPORTANT IMPORTANT THIS EQUIPMENT SHOULD NOT BE MODIFIED OR ADDED TO WITHOUT THE MANUFACTURER S AUTHORIZATION. THIS MANUAL WILL AID YOU IN THE SAFE OPERATION AND PROPER MAINTENANCE OF YOUR EQUIPMENT. READ MANUAL THOROUGHLY BEFORE ATTEMPTING OPERATION. IF ANY PORTION IS NOT CLEARLY UNDERSTOOD, CONTACT AN AUTHORIZED DEALER FOR CLARIFICATION. Altering this equipment in any manner which adversely affects the equipments operation, performance, durability or use, may cause hazardous conditions. To make sure you are fully aware of safety and service information, the following two symbols are used throughout this manual. This symbol is used throughout the manual to alert you to information about unsafe actions or situations, and will be followed by the word DANGER,, or CAUTION. DANGER indicates immediate hazards that may result in severe injury or death. indicates unsafe actions or situations that may cause severe injury, death and/or major equipment or property damage. CAUTION indicates unsafe actions or situations that may cause injury, and/or minor equipment or property damage. NOTE: This appears next to information or instructions which will help you operate and maintain your equipment the right way. Direct any inquiries to: Textron Golf, Turf and Specialty Products Attn: Director of Engineering P.O. Box 7708 Charlotte, NC USA SPECIFICATION INFORMATION All information contained in this manual is the latest available at the time of printing. Textron Golf, Turf and Specialty Products reserves the right to make changes at any time without notice. Whenever a name brand product is specified, an equivalent product may be used unless stated otherwise. CHANGE OF OWNERSHIP OR ADDRESS The information and instructions included in this manual alert you to certain things you should do very carefully. If you do not, you could: hurt yourself or others hurt the next person who operates the equipment damage the equipment. This manual contains essential operation and safety information and must remain with the unit at all times, within easy access of any operator. Textron Golf, Turf and Specialty Products makes every effort to keep owners informed of all safety related information. Therefore, changes in ownership and/or address should be reported to the manufacturer. Your dealer has REGISTRATION CHANGE FORMS which will be filled out and filed by the dealer for his records, and a copy will be sent to the manufacturer. DEALER INFORMATION For your nearest dealer location write to: Textron Golf, Turf and Specialty Products Attn: Sales P.O. Box 7708 Charlotte, NC USA In the USA and Canada call (dealer information only). Litho in U.S.A TEXTRON INC. All Rights Reserved. Lincoln, Nebraska Printed in U.S.A.

3 TABLE OF CONTENTS Operation Safety Decals Identification Model Number and Serial Number Service Parts and Support Material Specifications Towing Vehicle Specifications (Turf Trucksters) Towing Vehicle Specifications (Turf Utility Tractor) Set Up Set Up Instruction for Turf Truckster Power Cable Installation Tongue Installation Hitch Coupler Installation Reinstalling Side Panels Set Up Instruction for Tractor Removing From Pallet Installing Tines Operation Pre Operation Check Control Panel Before Starting Engine GA 60 Starting Procedure Beginning Aeration Aerating Depth Adjustment Maintenance Daily Maintenance Lubrication Fittings Air Cleaner Checking Element Installing Element Fuel System Fuel Filter Engine Choke Control Engine Oil Engine Oil Level Drive Chain Lubrication Towing Tire Pressure Daily Storage Tine Holders Tines Torque Chart Warranty

4 OPERATION SAFETY EQUIPMENT OPERATED IMPROPERLY OR BY UNTRAINED PERSONNEL CAN BE DANGEROUS This is heavy equipment. Improper use, or operating the unit in areas that may cause it to overturn, could cause serious injury or death to you the operator or bystanders. READ and understand the operator s manual before attempting to operate this unit. Immediately replace any warning and/or safety decal that becomes damaged or difficult to read. This product is heavy equipment and may present a crush hazard unless safety precautions are taken. DO NOT place hands or feet beneath unit at any time, unless engine is shut off and yellow uplatch bar is securing unit in UP position. Allow ONLY trained and authorized persons to operate this unit. NEVER allow children to operate this unit. Local regulations may restrict the age of the operator. Use ONLY the standard drawbar approved by the tractor manufacturer. The height from the ground to the top of the drawbar must be 3 to 9.7 inches ( mm). Never operate the unit while under the influence of alcohol or drugs. Never operate the unit while people, especially children, or pets are nearby. Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or property. BEFORE using the unit, always inspect it for problems. If something is wrong, DO NOT USE IT. Fix the problem before using the unit to prevent possible injury. WHILE using the unit, if something is found to be wrong, STOP using it. Fix the problem before the unit is used again. Operate the machine up and down the slope (vertically), not across the face of the slope (horizontally). ALWAYS use good judgement when operating on or near hills or slopes. NEVER start or stop suddenly, you may cause unstable operating conditions. NEVER change directions abruptly or make sharp turns on slopes. DO NOT place hands or feet near or under moving parts at any time. Check work area and remove foreign objects which may be a hazard to the operator, bystanders or damage the equipment. To prevent damage to the unit or other equipment, BE SURE all under ground obstacles are clearly marked. Make sure all shields and guards are in place to prevent possible injury. NEVER attempt to aerate in reverse. Always run unit engine where there is plenty of fresh air to prevent a buildup of carbon monoxide fumes. Carbon monoxide is colorless, odorless and deadly. NEVER run unit in an enclosed space where exhaust fumes will collect. Never use the unit in, or near an area where there is dust or fumes in the air which may be explosive. The electrical and exhaust systems of this unit will make sparks which could ignite explosive materials. DO NOT operate unit over any hard surfaces (driveways, sidewalks, etc.) with aerator heads in lowered position. Always stop engine and DO NOT smoke or allow open flames or sparks when refueling. Gasoline is extremely flammable and highly explosive under certain conditions. DO NOT remove radiator cap while engine is hot. Radiator contents are under pressure and spray may cause serious injury. Read this manual thoroughly to be aware of safe operating procedures. Gasoline is extremely flammable and highly explosive under certain conditions. Never remove the fuel tank cap or attempt to refuel the GA 60 or Turf Truckster while either engine is operating. 2

5 DECALS 2 PICTORIAL DECALS This symbol is used to show the possible result of working under the machinery without taking safety precautions. This symbol instructs the operator to read the service section of the operators manual. This symbol informs the operator and/or bystanders to keep a safe distance away from machinery. This decal instructs the operator to read and understand the operators manual. To prevent injury, they must be familiar with the operation of this product and be fully aware of all safe operating procedures. This symbol is used to show the possible result of operating the GA 60 without a tip over device attached to the towing vehicle. This symbol shows the towing vehicle being operated with a tip over prevention device in place. This symbol is used to inform operators of the possiblity of hazardous conditions. This symbol warns the operator to keep hands away from hot radiator cap. This symbol instructs the operator to read and understand the operators manual. To prevent injury, they must be aware of safe operating procedures. This symbol shows fingers and hand being cut or severed. DO NOT place hands and fingers under GA 60 while operating the unit. This symbol informs the operator and/or bystanders to keep a safe distance away from machinery. This symbol shows toes and feet being cut or severed. DO NOT place toes or feet under GA 60 while operating the unit. 3

6 2 DECALS PICTORIAL DECALS This symbol shows the position of the up latch bar pin when the heads are in the up and locked position. Also shown is the pin position for the unlocked position. These operation decals show the auxiliary transmission in low range and the drive transmission in low gear. Use the decal that corresponds with the Turf Truck you are operating (refer to page 5 of this manual). The various engine speeds are also shown with the corresponding hole spacing. 660CC N/MIN MM (INCH) (3 /2) (4) (4 /2) (5) N/MIN MM (INCH) (3 /2) (4) (4 /2) (5) MM (INCH) (3 /2) (4) (4 /2) (5) N/MIN CC N/MIN MM (INCH) (3 /2) (4) (4 /2) (5)

7 IDENTIFICATION 3 3 IDENTIFICATION THESE IDENTIFICATION NUMBERS MUST APPEAR ON ALL CORRESPONDENCE CONCERNING THIS UNIT. 3. MODEL NUMBER & SERIAL NUMBER Both the Model Number and Serial Number are on the identification nameplate located on the right side of the tool box by the gas tank (See Fig. ). Figure. Identification Nameplate 4 SERVICE PARTS AND SUPPORT MATERIAL Description Part Number Drive Belt Chain, #50 sealed roller, 69 links Connector, #50 sealed Element, Fuel Filter Element, Air Filter Element, Oil Filter Condenser, Ignition Spark Plug Points, Ignition Rotor, Ignition Chain Lubricant, Spray Wool Grease Parts and Maintenance Manual Coring tines See page 22 Touch up paint, Jacobsen Orange 6 oz. (.5L) spray qt. (.95L) can Black, 6 oz. (.5L) spray

8 5 SPECIFICATIONS 5 SPECIFICATIONS (subject to change without notice) Aerating Width: 60 (524 mm) Engine: Bore 2.62 (66.5 mm) Stroke 3.9 (8 mm) Displacement 5.7 cu. in. (847 cm3) Compression Ratio 9.5: Cylinder Compression 23 PSI at 400 RPM (486 KPa at 400 RPM) Horsepower 33 h.p. at 3600 RPM Engine Rotation (viewed from flywheel) counterclockwise Spark Plug Gap.032 (0.8 mm) Breaker Point Gap.07 (0.43 mm) Ignition Timing 0 BTDC at 000 RPM Idle Speed 300 RPM (minimum) Valve Clearance (Hot) Intake.00 (.25 mm) (Hot) Exhaust.02 (.30 mm) Equipment Height: 42 (067 mm) Equipment Length: 0 (2565 mm) (GA 60 alone) 72 (4369 mm) (with 3 wheel Turf Truckster) Equipment Weight: 2209 lbs. (002.8 kg) with 440 lbs. (99.7 kg) carried on Turf Truckster Equipment Width: 92 (2337 mm) Hole Spacing: 3 /2 to 5 variable (89 mm to 27 mm) Penetration Depth: 2 /2 (64 mm) to 4 (02 mm) maximum (depending on soil conditions) Truckster Speed: Engine: 2300 RPM (maximum during aeration) Aeration: 500 to 2300RPM Transport: Reasonable safe speed (0 mph max.) Use caution when towing aerator at speeds above 5 M.P.H. Standard Tines: Type: Hollow, tapered (self cleaning) Material: Through hardened steel Quantity: 24 tines per unit Sizes: 3/4 (9 mm) Tires: Size: x 2 High flotation Recommended Pressure 8 psi 5.2 TOWING VEHICLE SPECIFICATIONS (Utility Vehicles) NOTE: It is recommended that an 8720 or later model Cushman Turf Truckster be used to tow and operate the GA 60 aerator. The following towing vehicle specifications must be met to insure proper and safe operation of the GA 60. Minimum towing vehicle weight 000 lbs. (454 kg) Hitch height approximately 3 /4 (794 mm) for 920 and prior models and approximately 25 (635 mm) for 920 and later models. Vibration dampening hitch required. Mechanism to insure towing vehicle will not tip over backwards when attached to GA 60. Brakes 7 (78 mm) hydraulic (minimum) on axle with most weight. Brake light system to power the electric brakes. Hydraulic system requirements: 800 psi minimum at 5 gallons per minute. Variable speed governor (22 H.P. minimum engine size). Mechanical transmission and drive to prevent change in ground speed. Ability to maintain constant 2 mph speed with governed engine for 3 /2 5 (89 mm to 27 mm) core spacing. 5.3 TOWING VEHICLE SPECIFICATIONS (Turf Utility Tractor) Minimum weight of turf utility tractor 2700 lbs. (225 kg). 2 volt negative ground electrical system. Standard drawbar approved by tractor manufacturer. Drawbar height must be inches ( mm) from ground to top of drawbar. Hydraulic system with 800 to 2250 psi (2.4 to 5.5 MPa) maximum pressure. Minimum output of 3 gallon per minute (.4 L/min). Quick couplers located at rear of tractor. Braking system capable of controlling the tractor and the towed GA 60 weighing 2300 lbs. (044 Kg). Governor and properly geared transmission capable of controlling ground speed from to 2 mph (.6 to 3.2 km/hr) while aerating. 6

9 SET UP 6 6 SET UP 6. SET UP INSTRUCTIONS FOR CUSHMAN TURF TRUCKSTER IMPORTANT TO UTILIZE YOUR CUSHMAN TURF TRUCKSTER AS A TOWING VEHICLE FOR THE GA 60, THE FOL- LOWING KITS/ACCESSORIES SHOULD FIRST BE INSTALLED ON THE TURF TRUCKSTER:. Quick disconnect power cable installation kit (parts included in the GA 60 loose parts bag). 2. Hydraulic remote coupler kit (Part No ) for 9020 Turf Truckster models and prior or hydraulic system for models 90 and later. BE SURE there is adequate cable length to connect to the GA 60 and for turning either direction without disconnecting the power cable. To prevent sparks, disconnect the negative ( ) battery cable before installing power cable.. Locate the right side backrest support bracket on the seat back. Just below the bracket on the support panel flange is an existing 5/6 (8 mm) hole. 2. With () one /4 20 x /4 screw, nut and lockwasher from the loose parts bag, loosely attach power cable connector to support panel flange using existing 5/6 (8 mm) hole. See figure Fifth wheel and electric brake control installation kit. NOTE: To utilize 5th wheel implements not equipped with tongue extensions on model Turf Trucksters, use 5th wheel hitch kit (Part No ). To use 5th wheel implements equipped with a tongue extension on 870 & later Turf Trucksters, use 5th wheel hitch kit (Part No ). 4. Tachometer Variable speed governor. 6. Hydraulic system : ratio auxiliary transmission (920 & prior). 8..6: ratio 2 speed standard differential (920 & later). During transport with the aerator heads raised, the GA 60 can be transported at any reasonable safe speed (0mph maximum) ALWAYS use extreme care when towing aerator at any speeds above 5 mph. 6.2 POWER CABLE INSTALLATION NOTE: These instructions are for persons using Cushman Turf Truckster (8720 and later) models , , , , and to tow their GA 60. If using towing vehicle other than the Turf Trucksters listed above, use good judgment in finding a suitable mounting location for the power cable Figure 2. Power Cable Assembly 2. Mounting Hardware 3. Support Panel Flange 3. Before drilling a second mounting hole, mark the hole location by placing a pointed object (punch, awl, etc.) through the second hole in the power cable connector and lightly scratching the surface. 4. Rotate power cable connector away from the second hole location to allow easier access for drilling. 5. Drill second mounting hole using a /4 (6.5 mm) drill bit. 7

10 6 SET UP 6. Rotate cable connector back to original position and secure with () one /4 20 x /4 screw, lockwasher and nut from the loose parts bag. Tighten all hardware. 7. Connect eyelet end of black cable to vehicle frame negative ground location using existing hardware. 8. Using the existing hardware on the starter solenoid (located on the stopwall), connect the red cable end from power cable connector to the solenoid post the positive cable from the battery is connected to. 9. Reconnect the negative ( ) battery cable to the battery. 6.3 TONGUE INSTALLATION CAUTION The tongue components are very heavy. To avoid injury, BE SURE to have assistance when lifting or moving any of these components. 5. Carefully slide tongue components out from under sides of GA 60 and remove from pallet. 6. Loosen the right side top cover panel and raise till latched in the UP (raised) position. CAUTION Use caution when removing upper side panel mounting screws. When screws are removed from panel, the panel inner support assembly will become loose and could fall. 7. Remove both upper side panels, both lower panels, upper support assemblies and lower support brackets. Retain mounting screws. To prevent possible injury to yourself or others, stay clear when cutting banding. Banding is under tension and may snap back when cut. Wearing leather gloves or similar protection will help protect hands from sharp edges when removing banding from shipping pallet. DO NOT operate equipment until you have thoroughly read and completely understand the controls and operation sections of this manual. If anything is not completely understood, contact your CUSHMAN dealer for clarification before operating equipment. 8. Loosen and remove all hardware including isolation mounts from (2) two unpainted shipping plates located at the tongue mounting locations. Refer to Figure 3. Retain all original hardware except nuts.. Loosen and raise left (facing front of unit) top cover and latch in the UP (raised) position. 2. Open air duct lid and remove loose parts bag from tool box Carefully cut and remove all banding securing the GA 60 tongue components to the shipping pallet. 4. Turn jack handle counterclockwise to raise jack. Pull locking pin from jack and swivel jack towards rear of unit. Using the locking pin, lock the jack in the UP (raised) position. Figure 3. Shipping Plate 2. Isolation Mounts 3. Upper Support Assembly 9. Discard shipping plates and the four (4) nuts removed with each plate. 8

11 SET UP 6 0. With three (3) 5/8 x 4 hitch bolts, attach right side tongue tube to main frame assembly. See Figure 4. Attach left side tongue tube to frame. Do not secure at this time Figure 6. Long Tongue Extension (used when towed w/tractor) 2. Hose Support 2. Torque the six (6) 5/8 x 4 hitch bolts to 20 ft. lbs. (62 to 63 N m). Torque the four (4) 5/8 x 5 screws to 20 ft. lbs. (62 to 63 N m). Figure 4. Tongue Tube 2. Mounting Hardware. Using four (4) 5/8 x 5 screws, lockwashers, nuts and eight (8) thrust washers, attach short or long tongue extension to right and left tongue tubes. See Figures 5 and 6. NOTE: When using the long tongue extension, attach the hose support to the tongue extension as shown in Figure Cut tie strap and uncoil hydraulic hoses, power cable, and control panel cable and route them down the right (facing the front of unit) side of tongue, securing them with tie straps. The hoses should then be routed through the hose support on the fifth wheel of the towing vehicle. 6.4 HITCH COUPLER INSTALLATION. Raise the tool box lid and remove the hitch coupler. Attach the hitch coupler to the tongue extension using two (2) /2 3 x 4 /4 screws, nuts and lockwashers. 2. Torque the two (2) screws to 75 ft. lbs. (02 N m). 6.5 REINSTALLING SIDE PANELS Figure 5. Short Tongue Extension (used when towed w/turf truckster) Reinstall both upper side panels using all original hardware except for nuts. Replace shipping nuts with new centerlock nuts from loose parts bag. NOTE: For easier installation of the lower side cover panel, attach the panel bracket to the inside of the panel using double sided tape or a similar material. 2. Using original retained hardware, reinstall both lower side cover panels. 3. Unlatch and lower both top cover panels and secure in the DOWN (lowered) position. 9

12 6 SET UP 6.6 SET UP INSTRUCTIONS FOR TURF UTILITY TRACTOR. Install and secure a 2 (5 mm) tow hitch ball to the standard tractor drawbar. BE SURE the hitch ball is a class 2 (3500 lb. capacity) or better ball. 2 CAUTION Use ONLY the standard drawbar approved by the tractor manufacturer. The height from the ground to the top of the drawbar must be 3 to 9.7 inches ( mm) Figure 7 2. Mount power cable assembly (Part No. 8897) in a suitable location at the rear of the tractor. Connect the red cable end to the same post the tractor positive battery cable is attached to. Connect the black cable to a good ground on the tractor frame. Refer to wiring diagram. NOTE: Cable lengths and eyelets may need to be modified depending upon the configuration of your tractor. 3. Mount the GA 60 control panel at a location within arms reach of the tractor operator. Connect the control box harness (Part No ) to the GA 60 main harness (Part No ). A wire harness extension (Part No ) may be used if additional wire harness length is required. This extension is included in the long extension accessory (Part No ). 4. The wheel brakes on the GA 60 are NOT USED when towed with a turf utility type tractor. The brake bypass jumper (Part No ) must be plugged into the wire assembly (Part No ) on the GA 60 control panel. See Figure 7. If the brake bypass jumper is not installed, the GA 60 engine will not start. Refer to wiring diagram.. Brake Bypass 2. Control Panel NOTE: The GA 60 brakes are not utilized therefore the towing tractor must weigh a minimum 2700 lbs. (225 Kg). The tractor brakes must be capable of controlling the tractor and the 2300 lb. (044 Kg) GA Determine what type and size hydraulic quick couplers are used on the towing tractor. Change the ends on the GA 60 hydraulic hoses to match the towing tractor hydraulic fittings. Add to hydraulic hose length if required. 6. Attach long tongue extension to 2 (5 mm) hitch ball on tractor draw bar. Route the wire harness, power cable and hydraulic hoses through the hose support mounted on the long tongue extension. 7. Connect wire harness, power cable and hydraulic hoses to tractor. Remove GA 60 from pallet as described in the following section. 8. With the GA 60 engine turned off and the heads in the UP position, pull and turn the tractor fully to the left and right. Make sure all hoses, wiring and hitch move freely and are not rubbing against adjacent parts. 9. With the GA 60 heads in the UP position, disengage the uplatch bar shown in Figure 8. Start the GA 60, move to a turf area and lower the aerator heads. Lowering the aerator heads will increase the GA 60 engine speed and will engage the aerator 0

13 SET UP 6 drive as it lowers. The aerator drive will disengage and engine will return to idle when the aerator heads are raised. NOTE: If raising the hydraulic lever lowers the aerator, the hydraulic lines are reversed. Reverse the hydraulic lines at the quick couplers. 0. The GA 60 can produce a maximum hole spacing of 5 (25 mm). Hole spacings larger than 5 (25 mm) will SEVERELY DAMAGE the aerator mechanism. NOTE: The tractor speed MUST BE kept below 2 mph (3.2 km/hr) when aerating. BE SURE to use an engine speed and transmission gear that will result in a hole spacing of less than 5 (27 mm). Aerating speeds exceeding the allowable 2 mph (3.2 km/hr) will SEVERELY DAMAGE the aerator mechanism components. Tractor Hole Spacing Chart Approximate time needed to drive 00 Miles Per Hour Hole Spacing Inches (30.5 Meters) (Km/hr.) (mm) 34 seconds 5 seconds 68 seconds During transport with the aerator heads raised, the GA 60 can be transported at any reasonable safe speed (0mph maximum) ALWAYS use extreme care when towing aerator at any speeds above 5 mph. NOTE: The GA 60 may be damaged if towed on a flatbed trailer without the aerator heads lowered. Place boards or similar type material on the trailer to prevent damage to trailer and/or tines when the heads are lowered. 6.7 REMOVING FROM PALLET. Carefully cut and remove all banding securing aerator to shipping pallet. 2. Back the towing vehicle up to the GA 60. Position the towing vehicle so the tongue may be lowered onto the 5th wheel ball. 3. Loosen mounting clamp knob on rear of control panel to allow the control panel to be mounted on the right side hand hold of the Turf Truckster or towing vehicle. Tighten mounting clamp knob to secure. 4. Connect control panel cable from GA 60 to right side of control panel. Attach multi pin connector from the bottom of the control panel to the connector mounted on the right stopwall support. 5. Lock the hydraulic lift control on the Turf Truckster or towing vehicle in the float position to relieve hydraulic pressure. This will allow the hydraulic hoses to be connected more easily. NOTE: After connecting the hydraulic hoses, BE SURE to release the hydraulic lift control from the float position. 6. Connect the quick coupler power cable from the GA 60 to the Turf Truckster or towing vehicle. 7. Start the Turf Truckster or towing vehicle engine and raise the aerator heads slowly to lower the tongue onto the fifth wheel ball. Tighten ball grip to fifth wheel ball by turning square nut on hitch coupler clockwise until tight. 8. Raise aerator heads as high as possible to allow GA 60 to be removed from pallet. NOTE: Place various thickness boards or blocks in front of pallet to help prevent the GA 60 from dropping to the ground from pallet during removal. BE SURE aerator heads are raised to their maximum height to assure the turf guards do not catch on pallet. DO NOT allow anyone to stand directly behind pallet during removal of the GA 60. The weight of the unit may cause the pallet to slide back quickly when the GA 60 is removed. 9. Slowly drive the Turf Truckster or towing vehicle forward to remove GA 60 from pallet.

14 6 SET UP 6.8 INSTALLING TINES DO NOT attempt to install tines with either the aerator or towing vehicle engine running. Remove key from towing vehicle and disconnect power cable to GA 60 to insure that neither engine can be started during tine installation. Set parking brake on towing vehicle. 2 3 Before installing tines or performing any work under the GA 60, always lock the uplatch bar in place to prevent the accidental lowering of the aeration heads or the lowering of the heads due to a loss in hydraulic pressure. To lock uplatch bar, remove the pin under the rear of the bar and move it to the upper hole, making sure the pin passes through the uplatch bar to lock it in place. See figure 8. Figure 8. Uplatch Bar (Locked position) 2. Pin 3. Lower Hole. Insert three (3) tines per holder and torque screws (see torque chart). BE SURE tines are tight against shoulder on tine holder. Open side of each tine should be positioned towards the rear of the machine for proper ejection of cores (See Fig. 9). Figure 9 2

15 OPERATION 7 7 OPERATION 7. PRE OPERATION CHECK. Check grounds area and remove foreign objects which may be a hazard to the operator or could damage the equipment. 2. Visually check all moving parts and fasteners, if broken or loose, replace or tighten. Check for broken or bent tines, replace as necessary. 3. Make sure that all shields and guards are in place. NEVER make adjustments or perform any maintenance while the engine is running. 7.3 BEFORE STARTING ENGINE Always run unit engine where there is plenty of fresh air to prevent a buildup of carbon monoxide fumes. Carbon monoxide is colorless, odorless and deadly. NEVER run unit in an enclosed space where exhaust fumes will collect. Never use the unit in, or near an area where there is dust or fumes in the air which may be explosive. The electrical and exhaust systems of this unit will make sparks which could ignite explosive materials. DO NOT operate unit over any hard surfaces (driveways, sidewalks, etc.) with aerator heads in lowered position. Always stop engine and DO NOT smoke or allow open flames or sparks when refueling. Gasoline is extremely flammable and highly explosive under certain conditions. 4. BE SURE turf truckster stabilizer tube is in place before operating GA 60. Refer to decal illustrated above. 7.2 CONTROL PANEL Figure 0. Water Temperature Gauge 2. Hour Meter 3. On/Off Switch 4. Starter Button 5. Oil Light 4 DO NOT place hands or feet beneath unit at any time, unless engine is shut off and yellow uplatch bar is securing unit in UP position. Always use good judgment when operating on or near hills or slopes. NEVER start or stop suddenly. NEVER change direction of unit abruptly or make sharp turns on slopes. ALWAYS drive straight up and down the face of slopes, NEVER across the face of slopes. NEVER attempt to aerate in reverse. NOTE: Use extreme care when backing unit. DO NOT back unit with aerator in DOWN position. The tines and tine rams may be severely damaged.. Check engine oil level with aerator heads lowered and add oil if necessary. See engine oil section for type and quantity of oil. 2. Fill GA 60 fuel tank with gasoline. See fuel section for type and quantity of fuel. 3

16 7 OPERATION 7.4 GA 60 STARTING PROCEDURE. Set ON/OFF toggle switch in ON position and depress start button. Release start button as soon as engine starts. Allow approximately 5 minutes warm up time for engine before beginning aerating. NOTE: NEVER depress start button while engine is running. Starter drive and flywheel ring may be damaged. CAUTION To prevent possible breakage of hydraulic lift cylinder brackets on frame, unit MUST BE resting on down stops while aerating MM (INCH) (3 /2) (4) (4 /2) (5) N/MIN DECAL NEVER use the hydraulic lift cylinder to adjust depth of aeration. 7.5 BEGINNING AERATION BE SURE electric brakes are working properly before beginning aeration. NEVER operate the GA 60 if the brakes are not adjusted correctly. Refer to electric brakes section. 660CC N/MIN DECAL 2 MM (INCH) (3 /2) (4) (4 /2) (5) Place the governor control lever in DOWN position. 2. Depress foot throttle pedal down to the floorboard. 3. Refer to decal to obtain desired RPM and hole spacing for the Turf Truckster you are operating. Decal : is for all Trucks manufactured prior to Aug (Check ID plate for year of manufacture.) Decal 2: is for Trucks with a 660 engine and manual transmission. Decal 3: is for Trucks with a 970 or diesel engine with manual transmission. Decal 4: is for Trucks with a 660 engine and automatic transmission. 4. Raise foot from throttle pedal to allow engine to return to idle speed. 5. Depress clutch pedal and place transmission gear selector in FIRST gear. N/MIN DECAL 3 MM (INCH) (3 /2) (4) (4 /2) (5) NOTE: Aerating in a higher gear will damage the aerating mechanism and will also result in poor hole quality. 6. Shift Turf Truckster auxiliary transmission into LOW range. 7. Slowly release clutch pedal to engage clutch while depressing foot throttle. 8. After reaching desired engine RPM s, slowly push hydraulic flow control lever down to lower aerating heads and begin aeration. 660CC N/MIN DECAL 4 MM (INCH) (3 /2) (4) (4 /2) (5)

17 OPERATION AERATING DEPTH ADJUSTMENT The GA 60 is designed to aerate at a MAXIMUM depth of 4 (02 mm). The operator should be aware that, in extremely hard soil, the machine may not be capable of pushing the tines 4 (02 mm) into the ground. DO NOT operate with the depth setting at the 4 (02 mm) maximum when the tines are only penetrating 2 3 inches (5 76 mm). Operating under these conditions will cause premature wear and/or broken components in the aerator linkage. If the aerator tires consistently ride up off the turf or bounce up off the turf, the ground is too hard. Moist ground is easier to aerate than dry ground and is also easier on the aerator mechanism. If aerating in soil with rocks or stones, additional penetration over time may not be possible. The operator must determine what depth is possible for that area and be sure he does not exceed that depth. Adjusting the depth from 2 /2 (64 mm) to 4 (02 mm) is accomplished by adjusting the /2 (3 mm) axle stop spacers shown in Figure. NEVER try to aerate at a depth greater than the soil conditions will allow. The operator must first make a test run, measure the depth of the holes, and set the depth adjustment to correspond. After aerating the area once or twice at that depth to loosen the sub soil, it may be possible to lower the settings each time until the 4 (02 mm) maximum depth can be accomplished without abusing the GA AGAIN Aerate a small test plot, measure the depth of the hole and adjust the depth setting on the GA 60 to match it. If aerating extremely hard soil, additional penetration is possible with added water, either by rain or irrigation. Figure. Downstop Block 2. Spacers 5

18 8 MAINTENANCE 8 SERVICE AND MAINTENANCE When performing service or maintenance work on the GA 60, ALWAYS lock the uplatch bar in place to prevent the aeration heads from being lowered accidentally or due to a loss in hydraulic pressure. Set the park brake on the tractor. If any type of work is to be performed on the GA 60, disconnect the power cord and remove the key from the towing vehicle. This will prevent the GA 60 and the towing vehicle from being accidentally started. When replacement parts are required, use genuine RYAN parts or parts with equivalent characteristics such as type, strength and material. Failure to do so may result in product malfunction and possible injury to the operator and/or bystanders. NEVER attempt to perform service or maintenance functions on the GA 60 if you are UNTRAINED or UNAUTHORIZED. Improper maintenance can and will cause hazardous conditions. For necessary maintenance and service, contact your authorized RYAN dealer. When it is necessary to raise the GA 60PT for any repair or service, use jackstands to help provide adequate support. DO NOT rely on hydraulic or mechanical jacks for support. Immediately replace any warning and/or safety decal that becomes damaged or difficult to read. To reduce hazard of fire, always keep engine free of excessive grease. If fuel system leakage is detected, repair leak immediately. DO NOT operate unit until leak is repaired. ALWAYS stop engine and do not allow open flames or sparks when performing any maintenance function involving gasoline. This product is heavy equipment and may present a crush hazard unless safety precautions are taken. DO NOT operate equipment without all shields and guards in place. To prevent possible injury, keep bystanders a safe distance away from machinery. DO NOT make any adjustments or perform any maintenance while the engine is running. BE SURE to read the service section of this operators manual and the parts and maintenance manual prior to performing any service work on this product. 6

19 MAINTENANCE 8 8. DAILY MAINTENANCE Check the tire pressure (8 psi, 24 kpa). 2 BE SURE the weight is off of the tires. Lubricate axle pivots with a standard lithium based grease. 3 Lubricate aerator drive chains with chain lubricant spray (Part No ). 4 Lubricate belt idler pivot with a standard lithium based grease. 5 Lubricate clutch linkage bellcrank with a standard lithium based grease. 6 Clean radiator intake screen. 7 Check radiator coolant level. 8 Check engine oil level. LUBRICATION CHART Clutch Linkage 2. Belt Idler 3. Axle Yoke 4. Axle Yoke 5. Axle Yoke 8.2 LUBRICATION FITTINGS There are five (5) lubrication fittings that should be lubricated daily with a standard lithium based grease. Three (3) fittings are located on the rear axle yoke assemblies. Refer to Figure 2 for lubrication points. 3 NOTE: When lubricating the rear axle yoke assemblies, the wheels should be off the ground and the weight should be off the rear axle to allow proper lubrication of the yoke. One () fitting is located on the clutch linkage pivot tube, and the fifth is located at the drive belt idler pivot. The four (4) drive chains in the aerator head assembly should be sprayed with chain lubricant, spray (Part No ) each time the GA 60 is refueled, to greatly extend chain life. 2 FIGURE 2. Belt Idler Lube Fitting 2. Clutch Linkage Lube Fitting 3. Axle Yoke Lube Fittings (3)

20 8 MAINTENANCE 8.3 AIR CLEANER This is a large capacity, dry type air cleaner with a replaceable paper element. 8.4 CHECKING ELEMENT 2 Check element for damage, pin holes, etc. by placing a light source such as a flashlight inside. Figure INSTALLING ELEMENT. Filter Element 2. Filter Housing. Clean dust from inside of housing with a damp cloth. BE SURE dust does not enter intake. 2. Check all gaskets to make sure they are not loose or damaged. 3. Insert element into housing as shown in Figure Apply a light grease film to the nylon washer and wing nut. Secure element with washer and wing nut. NOTE: The dust collector empties automatically when properly installed with collector pointing DOWN. Refer to Figure 4 for proper positioning. Figure 4. Filter Assembly 2. Dust Collector 8

21 MAINTENANCE FUEL SYSTEM Fuel Capacity gal. (45.4 L) Gasoline good grade of non leaded only, 87 octane minimum GASOLINE CONTAINING ALCOHOL We DO NOT recommend the use of ALCOHOL bearing fuels in any of our products. The use of these fuels may create a potential safety hazard. See warning below. 8.7 FUEL FILTER The fuel filter is secured to the main frame just to the right of the fuel tank as shown in Figure Gasoline containing ALCOHOL can cause deterioration of some non metallic materials in the fuel system. Gasoline containing ALCOHOL will attract and hold moisture inside fuel tanks. Moisture may cause corrosion of metallic parts within the fuel system. Fuel leakage from a fuel system, may occur while the system is in use, in transit, or in storage. Such leakage can contribute to an explosion or fire causing serious bodily injury or death. NOTE: The use of alcohol bearing fuels may cause engine malfunction, particularly vapor lock at temperatures above 50 F (0 C). Figure 5. Fuel Tank 2. Fuel Tank Cap 3. Fuel Filter ENGINE CHOKE CONTROL The choke control of the GA 60 engine is automatically applied during starting and warm up to allow easier starting and smoother operation of engine (See Fig. 6). Remove fuel tank cap slowly. Fuel tank pressure may cause spray which can cause injury. Gasoline is extremely flammable and highly explosive under certain conditions. Never remove the fuel tank cap or attempt to refuel the GA 60 or Turf Truckster while either engine is operating. 2 Never refuel indoors. Always wipe up any spilled gasoline Never operate any equipment without an approved gas cap on the fuel tank filler opening. Figure 6. Fuel Pump 2. Petcock 9

22 8 MAINTENANCE 8.9 ENGINE OIL Engine Oil use only oils recommended for service class SG or SH Crankcase capacity quarts (2.7 L) RECOMMENDED SAE VISCOSITY GRADES Use SAE 0W30 SG or SH for all temperature ranges. Using oil other than the service classes listed, or oil change intervals longer than recommended, will greatly reduce engine life. Damage caused by improper maintenance such as incorrect oil quality and/or viscosity, are not covered under Cushman warranty. 8.0 ENGINE OIL LEVEL NOTE: The oil level must be maintained between the two marks on the dipstick at all times. NEVER overfill engine oil. Overfilling engine oil will cause overheating and damage may result. Engine oil should be checked with aerator heads down, and the tines resting on the ground to obtain an accurate reading. Checking oil level with the aerating heads in the RAISED position will give you inaccurate readings. To prevent possible explosion or ignition of vaporized fuel, DO NOT store equipment with fuel in tank or carburetor in enclosure with open flame (Example: Furnace or water heater pilot light). 8. DRIVE CHAIN LUBRICATION To prevent rust and prolong chain life, BE SURE the chains are well lubricated at all times. Use chain lubricant, spray (Part No ). 8.2 TOWING With the aerator heads raised, the GA 60 can be transported at any reasonable safe speed (0mph maximum) ALWAYS use extreme care when towing aerator at any speeds above 5 mph. NOTE: The GA 60 may be damaged if towed on a flatbed trailer without the aerator heads lowered. Place boards or similar type material on the trailer to prevent damage to trailer and/or tines when the heads are lowered. 8.3 TIRE PRESSURE The recommended tire pressure is 8 psi. DO NOT operate the GA 60 with over inflated or underinflated tires. NOTE: Improper inflation will greatly shorten the life of your tires. Caution must be used when re inflating or bringing a low tire to recommended pressure. Check air pressure with a gauge before connecting an air hose to a partly inflated tire. 8.4 DAILY STORAGE. Inspect and clean tines, replace any broken or damaged tines as required. 2. Check engine oil level and add oil if needed. 3. Check for loose or missing hardware. Tighten or replace as required before placing equipment back into operation. 20

23 TINE HOLDERS (Use 7/8 o.d. tines) (Use 3/4 o.d. tines) (Use 5/8 o.d. tines) (Use /2 o.d. tines) Tine Holder (Standard) Tines Used W/Holder (Standard) /4 Coring Tine /4 Coring Tine Tine Holder Tines Used W/Holder /4 Coring Tine /8 Coring Tine /2 Coring Tine /2 Carbide Tine /2 H.D. Tine Tine Holder Tines Used W/Holder /8 Coring Tine /8 Coring Tine /8 Coring Tine /8 Coring Tine /2 Coring Tine /8 Coring Tine /2 Solid Tine *Tine Holder Tines Used W/Holder /4 Solid Tine /4 Coring Tine *Turf guards (Part No ) must be used when using this tine holder. 2

24 0 TINES TINES Some of the tines illustrated have more than one part number listed below them. These tines are similar in design but may vary in length and/or diameter, for example: Part No (coring tine) is 4 /4 long with a coring hole of /2 x 2 /2 and Part No (coring tine) also 4 /4 long, has a coring hole of 5/8 x 2 /2. Illustrations are for reference only PART NUMBER ACTUAL LENGTH CORING HOLE SIZE TINE HOLDER USED APPLICATION Coring 4 /4 (08 mm) /4 x 2 /2 (6 mm x 64 mm) (5/8 o.d.) Less penetration (use on hard soils) Coring 4 /4 (08 mm) 3/8 x 2 /2 (3 mm x 64 mm) (5/8 o.d.) Less penetration (use on hard soils) Coring 4 /4 (08 mm) /2 x 2 /2 (3 mm x 64 mm) (5/8 o.d.) Less penetration (use on hard soils) Coring 4 /4 (08 mm) 5/8 x 2 /2 (6 mm x 64 mm) (3/4 o.d.) Less penetration (use on hard soils) Coring 5 /2 (40 mm) 5/8 x 3 3/4 (6 mm x 95 mm) (3/4 o.d.) Older greens with high soil content, fairways & tees with irrigation and no rocks Coring 5 /2 (40 mm) 3/4 x 3 3/4 (9 mm x 95 mm) (7/8 o.d.) Intensive fairway aerification or soil change in greens. Soil must be in good condition Coring 5 (27 mm) 3/8 x 3 /4 (0 mm x 83 mm) (3/4 o.d.) Older greens with high soil content, fairways & tees with irrigation and no rocks Coring 5 /2 (40 mm) /2 x 3 3/4 (3 mm x 95 mm) (3/4 o.d.) Older greens with high soil content, fairways & tees with irrigation and no rocks Solid Tine 5 (27 mm) /4 x 3 /8 (6 mm x 79 mm) (/2 o.d.) For drought conditions or areas that won t take water. For complete accessory, order Part No. 5405* Coring Coring H.D. 4 (02 mm) 4 /4 (08 mm) /4 x 2 /2 (6 mm x 64 mm) /2 x 2 /2 (3 mm x 64 mm) (/2 o.d.) (5/8 o.d.) Primarily used for light aeration for soil based greens and for overseeding. For complete accessory, order Part No ** Heavy duty tine with less penetration. Use on hard soils, sports turf Coring 5 /2 (40 mm) 5/8 x 3 3/4 (6 mm x 95 mm) (3/4 o.d.) Fairway & tee boxes with irrigation and no rocks. Renovation of sports turf Carbide Tip 4 /2 (4 mm) /2 x 2 /2 (3 mm x 64 mm) (5/8 o.d.) More durable tine with less penetration (use where tine wear rate is a problem) Coring 5 /2 (40 mm) 3/4 * x 3 3/4 (9 mm x 95 mm) (7/8 o.d.) Intensive aerification or soil or soil change. Soil must be irrigated and in good condition. Standard GA 60 tine Solid Tine 5 /2 (40 mm) /2 x 3 3/4 (3 mm x 95 mm) (3/4 o.d.) Heavy aeration when no clean up is desired. * 5405 Quint Solid Tine Accessory (includes tines, holder and turf guard). ** Quint Coring Tine Accessory (includes tines, holder and turf guard). 22

25 TORQUE CHART TORQUE SPECIFICATIONS HEX HEAD CAP SCREWS The torque values shown should be used as a general guideline when specific torque values are not given. U.S. Standard Hardware Grade SAE grade 5 * SAE grade 8 ** Flangelock Screw w/ Flangelock Nut Shank Size (Diameter in inches, fine or coarse thread) /4 5/6 3/8 7/6 /2 9/6 5/8 3/4 7/8 /8 ft. lbs N m ft. lbs N m ft. lbs N m * Grade 5 marking Minimum commercial quality (Lower quality not recommended). ** Grade 8 marking Metric Standard Hardware Grade Grade 8.8* Grade 0.9** Grade 2.9 *** Shank Size (Diameter in millimeters, fine or coarse thread) M4 M5 M6 M7 M8 M0 M2 M4 M6 M8 M20 M22 M24 M27 ft. lbs N m ft. lbs N m ft. lbs N m * Grade 8.8 marking ** Grade 0.9 marking *** Grade 2.9 marking

26 INDEX Aerating Depth Adjustment Aeration, Beginning Air Cleaner Before Starting Engine Beginning Aeration Checking Element Choke Control Control Panel Daily Maintenance Decals , 4 Depth Adjustment Drive Chain Lubrication Engine Choke Control Engine Oil Fuel Filter Fuel System Hitch Coupler Installation Identification Installing Element Installing Tines Lubrication Chart Lubrication Fittings Maintenance Model Number Oil, Engine Operation Operation Safety Power Cable Installation Pre Operation Check Reinstalling Side Panels Removing From Pallet Safety, Operation Serial Number Service Parts and Support Material. 5 Set Up Set Up Tractor Set Up Turf Trucks Side Panels, Reinstalling Specifications Specifications, Tractor Specifications, Truck Starting Engine, Before Starting GA Storage Tine Holders Tine Installation Tines Tires Tongue Installation Torque Chart Towing Tractor Specifications Truck Specifications Warranty